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Discussion Starter #162
Sweet looks brand new, maybe better than brand new....even the oil fill cap
yeah, I try not to miss much when I paint the engine..lol.
 

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Discussion Starter #164
update: ok, just as I figured, the concept of putting a ele front diff In a manual full front drive system ?..AINT FREAKING GONNA WORK !. I don't know how everyone else was able to just cut a tad out of the frame, and the front diff drop right in, and bolt up ?, but no freaking way this is gonna work on this '99 trx450s ?..least not without doing some big time hacking away at the frame supports ??!. sorry outlaws, but as i've been saying all along, YOU JUST CAN'T TOSS PARTS AT SOMETHING, AND THINK ITS A EASY THING TO DO !. sooo, this front idea project just got busted big time !!. after looking at this for a few ?, there is no way this is going to work without doing some big time cutting away at the frame supports !. have a look at the pics, at each spot I focused on where are 3 area's are that bolt this to the frame, in each place, from what I see, I need about 1 inch drop or more in all 3 places to even get the bolt holes on the diff to line up with the mounting holes on the frame. and when you try this, as you can see, the front end at the pinion cases will sure enough hit the side support, and the only way to keep that from hitting it ?, is whack the heck out of it to clear. nope, not cutting any more of this frame. in the last pic, you can see how close I am to this support ?, in order to get the front diff to make all bolt holes, drop down far enough to be level with the front output drive shaft ?, i'd have to cut the crap outta that frame support, AND I'M NOT DOING THIS !. sorry outlaws, but this front diff plan just got busted big time !! :-(.
 

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The nose of the 2002-2004 electric shift diff is much bigger and longer , these frame pics are a 2002 and a 2000 frame , a 1999 frame has to be cut a lot for it to fit ---- it is not going to weaken the 1999 frame any more than a 2002 frame ----- scrape the electric diff and go with a 4x2 kick out , it is a much better set up anyways , less wires and expensive parts
 

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Discussion Starter #166
The nose of the 2002-2004 electric shift diff is much bigger and longer , these frame pics are a 2002 and a 2000 frame , a 1999 frame has to be cut a lot for it to fit ---- it is not going to weaken the 1999 frame any more than a 2002 frame ----- scrape the electric diff and go with a 4x2 kick out , it is a much better set up anyways , less wires and expensive parts
the problem is, is that upper support bracket that sits right next to the pinion end in my 3rd pic, in order to clear and bolt up ?, that support bracket has to be cut almost out near the lower part to frame. can't run a full time diff and 424 kick out, as both of these will run close to 1k alone..lol.
 

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Discussion Starter #167
on a pos note !, I did get the engine in the frame tonight, and some rear brake stuff installed :).
 

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can't run a full time diff and 424 kick out, as both of these will run close to 1k alone..lol.
.. if you don't have a diff laying around it can be expensive , have seen PSN has 450 F/T ( full time ) diffs for around $229 and a new 4x2 is $340 ( Dick's Cycles ) , it would be over $600 and then you would most likely reseal and bearing it , So $700 would be about right ---I recently seen a front diff for a 2000 450 go for $100 on Facebook and it looked might clean and you and me know a guy on this site who's got a brand new 4x2 that he might sell for a decent price , might be able to cut that $700 in half

..... cut the frame , Columbus took a chance and it worked out for him ..... what's the worst can happen , it fails and you can say I told you so ....LOL ... it will be ok , I have read many threads on the Foreman forums about this same mod
 

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Discussion Starter #169
can't run a full time diff and 424 kick out, as both of these will run close to 1k alone..lol.
.. if you don't have a diff laying around it can be expensive , have seen PSN has 450 F/T ( full time ) diffs for around $229 and a new 4x2 is $340 ( Dick's Cycles ) , it would be over $600 and then you would most likely reseal and bearing it , So $700 would be about right ---I recently seen a front diff for a 2000 450 go for $100 on Facebook and it looked might clean and you and me know a guy on this site who's got a brand new 4x2 that he might sell for a decent price , might be able to cut that $700 in half

..... cut the frame , Columbus took a chance and it worked out for him ..... what's the worst can happen , it fails and you can say I told you so ....LOL ... it will be ok , I have read many threads on the Foreman forums about this same mod
if it was mine ?, I would think on it, but seeing how this is not mine ?, I have to do what he wants, and I can't back up my work on this one bit !..lol. i'll wait to see what powerstrokes says ?, if he wants to cut the frame all to heck ?, so be it. but from where I stand ?, I won't do it as of right now. as for what can happen ?..i'd waste a lot of my time, my time is important to me fish, I don't have time for guess work !..lol.
 

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Discussion Starter #170
@fishfiles , no..the old front diff was destroyed big time, so I don't have a front full time front diff to use..let alone rebuild !..lol.
 

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brand new front diff from partzilla is only 452 and some change, i'll have to wait to hear from powerstroke and see what he wants to do ?.
If were me , I'd go for the $199 PSN diff and put that extra $253 towards a brand new 4x2 for $340 ------- if that PSN used diff looks and fells good , I'd get three new seals , fresh oil and roll with it ----he will never have to worry about flashing 4wd indicator lights and riding home in 2wd ---- kind of ironic that the complete full time diff cost $452 and that is almost the exact price of just the electric clutch on the front of the electric diff , then add in two sensors at $75 each and the price of the electric diff , wow , that is close to a grand for the whole set up , I have two of the electric diffs that I would sell , but no full timers that I would part with
 

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it is not going to weaken the 1999 frame any more than a 2002 frame
To me this is the factor that led me to notch this 350 frame for the 400AT front diff.
I looked at my neighbor’s 400AT frame, compared to my 350. Same crossmember is in both machines, and the engineers at Honda thought it was ok to notch the crossmember to fit the bigger diff.

Shade, you have an 02-04 450 there. Compare his frame to yours. (Of course, Fishfiles posted pics, but you’d be able to measure and closely scrutinize the difference since you have a 2nd Gen 450 on hand.
 

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Its not as bad as it looks at first glance shadetree. Just notch that crossmember the same as Honda did on the '02-'04 models.

I have a gizmo half built for it so ya gotta get out your grinder... :)
 

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update: ok outlaws, I got the frame notched. got the diff's bolt holes to line up, then I had to notch out the vertical frame support because it would be right on top of the pinion end collar boot, took care of that. now it was time to stab the drive shaft. oh boy..was not gonna go together at all !. lol. thought jeep sent me the wrong drive shaft ?, nope, measured mine, same drive shaft...hmmm..now what ?. after fighting it left and right, I decided it just wasn't going to push together, least not without my diff's bolt holes lining up ?!. so I had to pull it all back out, got to studying the drive shaft..hmmm..seems the drive shaft is compressing the spring, bottoming out inside the collar at the front output shaft at the motor ?. ok..soo..how do I make it compress more to give me that extra room to get the bolt holes to line up ?, you guessed it !..shorten the spring a few rounds, this allowed me to compress the drive shaft that 1/2 inch I needed to fit the drive shaft !. its still a tight fit ?!, but at least it will go together !!!. what a freaking pain this turned out to be !..lol. I don't think anyone who has done this bothered to mention anything about making the spring shorter ?, but if they ever take it apart ?, I highly recommend cutting the spring down a few winds, allowing the collar to compress more :).
 

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When I put the 2000 diff with the 4x2 into my 2002 it was hard to compress the shaft just like you mentioned -------- it was a jigsaw puzzle getting the diff on just the right angle to start the coupler and hard to roll the diff into position and get by the top mounting ears , once I figured out the procedure it goes easy
 

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update: got the whole front diff and drive shaft installed, this has me tired big time !. one problem I do not like ?, the front drive shaft coming out of the motor spins no problem, but the front ring gear is also turning even with me having an axle stuck in the side, and holding it back with a very good grip !?. something seems off on this ?, the ring gear should not be spinning at all !. gonna run a power test on it when I get a chance, and see if I hear the clutch click ?. other than this ?, here she is waiting on some front drive axles :).
 

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